Instrument box



July 23, 1946.. J. TARR 2,404,757

INSTRUMENT BOX Filedv June 6 1942 5 Sheets-Sheet 1 EMEHYURE James/7 3522/10. Ed d/l'" Good ear m y 3, 1946 I J. H; STARR ETAL 2,404,757

' INSTRUMENT Box Filed June e, 1942 s Sheets-Sheet 2 3 j I i I /3 UNSAFE FOAM Z sLowme 54 5H0RT ON f TEST v swrror:

' LONG OFF l I V j kiw ZEMEUYUE 5 efimesh" Starr f PLUG P417? 7 y 2 1946- J. H.-STARR ETAL 2,404,757

- INSTRUMENT BOX Filed June 6, 1942 5 Sheets-Sheet s y 23, 1945- J. H. STARR ET AL 2, 7

INSTRUMENT BOX Filed June 6,/1942 5 Sheets-Sheet 4 E1 i 6. 56-34 34.9v 5654" v 5 .34

Patented July 23, 1946 INSTRUMENT nox James HKStarr, La Grang, and Edward A.

Goodnow, Glenview, Ill., assignors to Electro- Chemical Engineering Corporation, Chicazgm. 111., acorporation of Delaware Application J une 6, 1942, Serial N0. 446,144

5 Claims. (01. 177-311) This invention relates to an instrument box or terminal box for anelectric control circuit.

More specifically the invention relates to a -boxlike unit suitable for mounting in the engineers cab of a steam locomotive and containing electrical devices adapted to indicate and automatically control foam conditions within the locomotive boiler. a 3

The box or unit' of this invention will be hereinafter specifically described and illustrated in connection with an automatic foam blow-01f system for a locomotive boiler, but his not limited to such preferred use since, for example, the illustrated electrical devices in the box can be rearranged or replaced to control a different type (ofsystem. The invention; therefore, includes, within its scope, many different forms :of units in addition to the illustrated unit for controlling many different forms of electrical .systemstin additionto the illustrated system.

A feature of the unit of this invention is its compactness .andthe arrangement of the parts therein for quick accessibility. i

.A further feature of the unit is its adaptability forv'use-with different types of systems which is made. possibleiby rearrangement of readily shift- .able bus bars or conductor links mounted in the unit.

Another feature of the 'box is the readily removable panelatherein which carries electrical devices adapted. to be placed in proper circuit relation withlother parts or devices in the box by the mere seating of the panel in the box. The panel can be removed to expose all underlying parts for devices in the box and to give free accessitoallparts or devices mounted on the panel.

The panel, when lifted out of the box, is com- ,pletelyseverecl .from all connection therewith,

since no pwiresl'needextend between. the box mounted'parts and thecpanel mounted parts 1 A still; furtherfeature :of the. invention is its readilyopenable "spare partscarrying cover and the light transmitting ports in the cover as well the wording on .the cover which .reveal at a glance theconditionof the system without necesan opening of the box. It is, then, an object ofthisinvention to proyidea unit, such asaterminal box, having aplution with other control devices mounted on aremovable panel adapted to be completely separated fromthe box;

A still further object of the invention isyto provide an instrument box with a sub-panel mounting for various electric control units which areplaced-in proper circuit relation by the mere act ofinser'ting the panel in position in the box.

A still iurtherobject of the invention is to provide an improved instrument box for automatic foam control systems.

Still another object of the invention is 'to provide an instrument box adapted for mounting in the engineers cab of a steam locomotive to not only house control units for an automatic locomotive boiler blow-off system but for also visually indicating to the engineer the condition of the boiler water in the locomotive boiler.

Another object of the invention is to provide a standard instrument box unit for automatic blow-off control systems which contains readily shiftable conductor links or bus bars which can be arranged as desired to adapt the 'unitfor use with different types of systems; 7

Other and furtherobjects of the invention will 'be apparent to those skilled in the art from the following detailed description of the annexed section, to illustrate underlying parts of a 10ccmotive equipped with a three-electrode foam blow-off system automatically controlled from the instrument box of this invention which is illustrated ,in dotted lines as mounted in the engineers cab of the locomotive.

Figure @2 is a side elevational View of the instrument. box. 1 i 4 i t Figure 3 is a, front elevational view *of the instrument box .With the cover in "closed position.

Figure 14 is a front felevational view of the instrument boxw'ith the cover in open position and I with the detachable panel removed from the box. Figure 5 is a plan view of the front face of the removed panel. 7

Figure 6 is a plan .viewof the rear face of the removed panel. i 1

Figure '7 is a side elevational view of the removable or detachable panel, shown in Figures 5 and6. Figure 8 is a longitudinal cross-sectional view,

, with parts in elevation, taken along the line VIII VIII of Figure 4,

shell I! defining a boiler course l2.

fixedly mounted in the instrument box and illustratin said parts somewhat diagrammatically Figure 13 is a wiring diagram of the parts on in somewhat diagrammatic form.

As shown on the drawings:.

In Figure 1 the reference numeral l designates generally a locomotive having the usual boiler A'fire box I3 is provided in'the rear end of the boiler and fire tubes such as M project forwardly from the firebox through the. boiler course. The usual engineers cab I5 is mounted around the rear endjof theboilen. j g @Anopening I 6 is provided in the top of the boiler shell Hjand theopening is covered with the, usual steam dom l1. 1 A steam throttle pipe 18 or main outlet pipe to the operating cylinders of the locomotive-extendsupwardlyat its inlet end intothe steamdome'l'l.

The locomotive boilencont'ainsboiler water B. to a, level L. Aste'am space S. S. is provided above the boiler water and this steam space ex- .toprovide an elongated channel or non-steam generating course in the steam space of the boiler. 'IZheside and endwalls project into the steam the top of the boiler shell so as to place the entire interior ofrtheboxi alon its length in communicationwith the steam space.

As foam or light water develops'above the level Li 1i theboiler, it v will be intercepted by the .trough andispill into the trough so as to prevent entrainment with the steam entering the steam dome. {Asa resultof this collection of foam or light water in thetrough, a higher quality steam the detachable panel and illustrating such parts 2,404,757 j f' f 1' on the locomotive for supplying the compressed air to a pipe line 26a which, as will be hereinafter explained, furnishes the compressed air to a solenoid operated valve which valve in turn can be opened to supply the air to the pipe line 26 and then to the blow-off valve 2|.

Three electrodes 21',- 28, and '29; project from the top ofthe boiler shell H into-theysteam space S. S. of. the boiler. The electrode 21 is quite short and depends into the steam space to terminate a short distance beneath the boiler shell. The electrode 28 is somewhat longer than the electrode 21 and depends into the trough l9 prefer-1 ably to a level just beneath the top of the trough. The electrode 29 is quite long and extends into the bottom portion of the trough I9.

The instrument box 30 of this invention is mounted on the rear wall I la of the boiler in the 7 space S. S. but terminate in spaced'relation below is delivcredto the throttle pipe and foaming to a ,leve1 sufiicient to vented. A The bottom portion of the trough l 9 communicates with a drain pipe 20 discharging into an .air pressure, operated blow-off valve 2|. The blow-off. valve is :mounted n to of the boiler shell-H; and discharges through a pipe 22 into a enter. the throttle pipe is presteamvandwater separator 23 also mounted on .valve 24 for actuating: the same through a pipe line '26. A compressed air tank T can be mounted engineersv cab i5, and contains electrical control devices in circuit arrangement with the electrodes 21, 28, and 29 and with an electric generator, battery, or other source of electriccurrentjh If desired a steam operated turbo -generator can be usedto supply the electricity to the circuit. Such a generator can be conveniently driven by steam generated in the boiler. I

The control devices in the box 3fl not only give the engineer a visual indication of foam conditions in the boiler butalso automaticallyeffect the opening and closing of [the blow-01f valve 2| to discharge the foam out of the trough l9 whenever it is collected therein in suflicient amounts above predetermined levels.

As best shown in Figure i, the instrument box 3i! comprises a rectangularmetal housing having side walls 32 and top wall E l, a bottom wall an a rear wall 3t. The metal housing, as in,-

dicated in Figures 1 and 2, is mountedin-upright position on the rear wal1 I la of the boiler and for this purpose apertured mounting. flanges 34' and 35' are formed on the rear end. of the box to project above the top wall 34' and below the bottom wall 35 respectively. a

One of the'side-walls suchasithe wall 32 has hinge bosses 31 and 38 projecting laterally. there from near the top and bottom ends thereof. The other side wall, suchas the wall 33,.carries a bracket 3!) with laterally extending spaced apertured ears 39 receiving. therethrough a swivel pin 4t and receiving therebetweena swing bolt 4 I.

' A cover 42 having a pair'of apertured ears 43 the entire. front'of theibox .will be exposed as shown inFlgure .4: The cover has a'ifurcated flange 46 .on the free side-thereof. adapted to "forjfholding the cover 'thatspare fuses Elf and spare bulbs52 can be carried in the cover; The cover thus serves as asp'are parts'carrier. T

w The cover is also apertured at three different locations to receive bulls-e-yellenses 53, 54, and 55 for transmitting light from bulbs mounted in the box as will be hereinafter described to visually indicate to .the engineer the foam condition in the boileras well as the functioningof thefoam controltapparatus.

The top wall 3 5 of the housing has a :boss. 55 in which is secured the end of a pipe or. conduit 51 for a cable I) containing wires-27, 28'; 29' and Bifrom the electrodes and .battery as shown in Figurel. This cable .enterst'he topwall34 ofithe housing as best shown in Figure sland the various wiresthereof are connected as indicated tothe varioilsposts of a binding post panel. 58, mounted in the box at the upperend thereof.

'As best shown in Figures' l, 8 and 9, the hindin g post' panel'SB is carried on standards-or supports 59 from the rear wall flfilof the box. This panel 58 is made of Bakelite or other insulating material and mounts eight binding posts fill. some of the pairs of binding posts .61 as shown in Figure 4, are connected by means :oflinks such as 6 and some-of the binding posts fill are grounded to the metal housing by means of a link such as $2. These linlrs bl and t2 can :be switched around to adapt the box for use indifferent circuits as will be hereinafter morenfully described. I 'he panel-ia also mounts the female member of aneight-circuit plug 63. l

A f use bracket 6'4 is also mountedon the panel 58 for carrying a fuse 65 in the spring arms thereof. l i i A switch S1 is mounted on the inner .f ace of the sidewall 33 and this side wall is apertured to permitthe switch handle Hpto project there'- through for manual operation,- As will be hereinafter more fully explained, the switch S1 is an on and ofi switoh'to'throw the circuit into and out-of operation. L i A second switch S2 is mounted onthe inner face of the side wa'1l32 and this Wallis likewise apertured to receive'theret-hrough the operating handle H2 of the switch. This switch S2, as will 'be hereinafter more fully explained, is a testing switch for the long and short electrodes 28 and 27 respectively; i 1 As best shown in Figures 8 and '9,-the bottom wall 350i the housing-has an aperturedboss 35a thereon receiving a solenoid valve S. V. The

solenoid actuator for the valve proje'ctsthrough the boss into the interior of the housing while the valve proper depends from the bottom of the housing and serves to control the flow of compressed air to the blow-oft" valve 2!. i

As shown in Figure 4, and as also shown in Figures -'8 and 9, the lower corners of the housing have supporting blocks 56 formed therein and exe tending to a level beneath the openface of the housing. Threaded pins 51 projec'tfrom the up per-ends of these supports 66. I

Thelower pair of supportstt 'for the panel 58 have threaded rods 68 projecting" therefrom and carrying spacer sleeves 69 therearound. The spacer sleevestfi terminateat the same level with the ends of the supporting 'iblOCkS or bosses 66.

As shown in Figures 5, 6, 7 and 9, a removable panel 10 has apertures H in the corners thereof adapted to receive the threaded members 6'! and 68 respectively so that the panel will rest on the supporting bosses 68 and the sleeves 69 respectively in the housing. Nuts "H" are threaded on these members 61 and 68.. In thismanner. the panel 10 is readily mounted inposltion in th'e "housing and oan be quic'kly removed from the housing by mere removalof the nuts '11".

A ground strap '12, as shownin Figure 5-, can

be secured to the panel?!) to surround one of the threaded mem'bers'fi-l and to receive the-nut -11 tightly thereagai-nst for grounding -the entire panel to the box. J l

Anglestrips l3 and can be Welded or soldered to the :f-ront faoe of the panel 10 toact as light barriers toprevent light from any of the lamps 8 0, 8 and 82 from showing through any of the I bulls-eyes 53,54 and not associated with the lamp which may at the tinreloe-lig-hted. a

As also shown in Figure 5 the front or outer iace of the panel It carries a fuse "bracket 15 with spring clips receiving a fuse 76. The panel' is apertured .as at 1'3 and 18 to receive insulation grommets l9 permitting the passage of wires bee can be held in the aperture 85 by means of two boltsipassing through the panel 1i Astrap 'SL'secured to thepanel we, candoe used as. a-handle to assist in removing panel .16) from theinstrument box 30;,

.Asoshown in Figures 6 and 7, time delay :switch' W: is mounted on the] rear .face of :thepaheliil together with threerelay switches v. sl, ill; and 93. Seven binding .posts 96 are.a'lso mounted onxt'he panel 13 andprojectfromthe rear face thereof.

ber of the plug 63 carried by the binding post panel 53. The timedelay switch ti! and the re lay switches SI will fit into amplespace provided in the housing as shown in Figure 9 so-as not to interfere with the switches or binding post panel in any manner. Likewise the binding. posts 94, and the links 85 of the panel 10 will clear the solenoid valve projecting into the housing;

As shown in Figures 10 and 11 the solenoid valve S. V. includes a cylindrical casing Hill which projects into the housing as shown in Figures 8 and 9 and which contains a sleeve It. A solenoid operating coil 192 is disposed. in the easing lull around the sleeve H3]. 1 A base I83 is provided for mounting the casing and sleeve. This base=can be secured tothe boss 35a of the'houslug... A top wall member m4 covers the leasing and is aperturedto receive aplunger [05 with a threaded shank H36 projecting upwardly therefrom. A capmember I67 receives the shank. I

inthreaded relation therewith and a locking nut I03 can be disposed above the cap around the shankllllfi' to lock the plungerat a fiX6d level,

The inner end of the plunger carries a plug I69 for seating the end of a coil spring I Ill. The coil spring acts against a movable plunger H! controlled by excitation of the coil l02.. The lower end of this movable plunger I'll projects into a valve casing H2 depending from the mounting basel03. The casing H2 has three ports H3, H4, and I [5. The port H3 receives the pipe line 26a from the compressed air tank T. The port 114 receives the pipe line 26 to the blow-off valve 2l;

The port II is a bleeder port adapted to exhaust compressed air from the pipe line 26. Air from the pipe line 26a enters a chamber ,IIB of the casing H2. This chamber contains a valve seat I H with a bore therethrough communicating with a second chamber H8 having the port H4. 1 A third chamber H9 containing the port I I5 is provided with a second valve seat 120 having a passageway therethrough in alignment with the passageway in the port In and also communicating with the chamber H8.

A valve I2I is carried by the movable plunger I II and is adapted to seat on the seat III for closing the passageway therethrough. A second valve I22 ,is mounted in the chamber I I9 and is adapted to seat on the seat I20 for closing the passageway of thisseat. The valve I22 can be- .carried on a spring urged plunger I23 seated in an end cap I24 at the bottom of the casing.

A ribbed or longitudinally grooved spacer. pin I25 is slidably mounted in the aligned bores or passageways of the seats H1 and I20 for engaging the valves III and I22.

When the solenoid coil I02 is energized the plunger III is drawn against the spring pressure i I 0'into the sleeve IOI therby unseating the valve I2I... This permits the spring acting on the valve I22 to close the valve I22 so that communication will exist between the pipes 26a. and. 26 thereby permitting the flow of compressed air to the blowoil valve and opening the valve to discharge the collected light Water and foam out of the trough ,I9. .When the coil I02 is ole-energized, the spring As shown in Figure 3, the-outer face of the cover 42 can have a name plate I30 bolted thereon and apertured in alignment with the apertures in the. cover to expose the various bull's eyes thereinl The plate I30 preferably bears legends such as Unsafe foam under the bulls-eye 55; Blowing above the bulls-eye 54; On and Oil; opposite the switch handle Hi; Test switchopposite the switch handle H2; Short above the switch handle H2; and Long below the switch handle H2. The bulls-eye 53 can have the legend On directly thereon. I

The switch handle H1, when moved to the"On" positionplaces the system in operation. With eye 53 will light up.

The Test switch handle H2 is ingof the apparatus to determine whether or not the system is in proper working conditionhWhen the switch handle H2 is moved to the Short positiomboth bulls-eyes 54 and55 should light up and the blow-off valve should open. Whenjthe switch handle Hzis moved to the Long position, the bulls-eye 54, after a time delay, should light up andthe blow-off valve should also open, This gives the engineera quick check on the op: erationiof the system "to determine vvhether or not it is in prop'er'working' order. H The switch handle"l-I2 isnormally in themiddlejpositionas the switch handle H1 in On position the bull's:

br a te t shown in Figure 3 and need not be operated for automatic functioningof the system. The wiring diagram of Figure 12 illustrates the connections to the female plug member 63 on the binding post panel 58 of the instrument box. As therein shown, one link 6| connects the post wired to the positive side 3I"of the battery 3I with the post wired to the positive side of the generator. A second link'BI connects the post wired to'the groundwithithe: post wired, to the negative side of, the battery. Another. post, marked Gen., as shown, is wired throughthe fuse 65 with the last mentioned post ontheneg: ativeside of the battery. All electrical energy is supplied from the generator when the links GI are in place. 'When the links BI are removed the battery is used to supply energy for the coils of relays 9|, 92 and 93 while the generator is used to supply energy for the coils of the delay switch and the solenoid valve S. V., as Well as for the lights 80, 8| and 02. .q The various wires. from the electrodes and from the battery and ground are connected to, the binding posts as indicated. The wires from the binding posts are all combined in acable and leadto the switches S1 and S2. The On position of theswitch S1 connects the binding post panel with the. solenoid Valve. The Shortv and Long positions of the switch S2 connect various circuits to effect a testing operation of the Short and Long? electrodes aswell as the operation of the solenoid valve. Y As shown in the removable panel wiring diae. gramvof Figure 13, themale member of the plug 63 has all of the prongs connected with wires from a cable and the various control devices receive; corresponding.v wires from this cable. Various bindingposts 94 are connected through the links 95 for proper circuit arrangements of the illustrated three-electrode system. If] a two'relectrode system is used, the connecting links are rearranged to disengage the corresponding control devices for the eliminated electrode.

When foam or light water spills into the trough I 9 and reaches a level sufficiently high to contact the extra long electrode 29, no current flows, as a relay switch contained in relay 93 is open. As the foam level rises into contact with the long electrode 2'8current will "flow through relay'92- to close its switch thereby causing. current to flow through the heater coil of time-delay switch 90. After a time delay, contacts of time-delay switch 90 will close, causing current to flow through relay 93 to close two of its switches and open one of its switches, thereby feeding current to the solenoid coil for opening the valve and to thelight for bullseye 54 to indicate that the system is discharging foam, feeding current through relay 93 and the extra long electrode to act as a holding circuit forrelay 93, and breaking the circuit, to" heater coil of time-delay switch 90, thereby causing its contacts to open.

Current will continue to flow through relay 93 until the level of foam in: trough Iii-subsides below the end of electrode 29, thereby breaking the holding circuit of relay 93 and permitting relay 93 to open, thereby breaking the circuit to the'solenoid .toclose thevalve and opening the circuit through the light for bulls-eye 54; j

When foam rises to a level suflicient to contact the short electrode 21 a third relay 9I is energized. This relay when closed effects the near that the foam-has reached an unsafe level in the boiler. Theenergizing' of relay 93 causes the closing of two of its switches and the opening of one'of' its switches, thereby causing opening of the solenoid valve; lighting of lightfor bulls-eye 54, closing of a holding circuit for relay 93, and opening of the time-delay switch heater circuit, all as hereinbefore described; If bulls-eye 55 remains-lighted for an. appreciable length of time, the: engineer should blow off the boiler through the manual means usually provided on a locomotive. When the foam level subsides away from the short electrode 2'! relay 9| will be deenergized, thereby shutting off the light -to bulls-eye 55. However, the solenoid valve will not be closed because it will be receiving current through relay 93 and will remain open and light the bulls-eye 54 will remain lighted until relay 93 is de-energized by foam level subsiding beneath long electrodes 29, thereby opening holding circuit of relay 93.

In a three-electrode system, therefore, the foam, light water and other impurities in the collecting trough first contact the extra long electrode 29 and, upon rising into contact with the long electrode 28 after a time delay, the closing of a circuit is effected to open the blowoff valve and to light the bulls-eye 54 thereby indicating that the system is blowing off. If foam development is quite rapid and rises to a still higher level so as to contact the short electrode 21, an additional circuit is energized to light up the bulls-eye 55 and thereby indicate to the engineer that bad foaming conditions exist in the boiler. If the top bulls-eye 55 remains lit for an appreciable time, the engineer may open a manually controlled blow-off for effecting a more rapid subsiding of the foaming conditions.

The top electrode, or short electrode, is useful as a safety device in the event that the long electrode 28 does not initiate the blowofi. Once the blow-off has been started by either or both the short and long electrodes, the blow-off will continue until the foamy water subsides below the level of the extra long electrode. Upon dropping away from the extra long electrode, the circuits will all be broken and the blow-off valve will close, but the level of impurities in the trough will be near the bottom of the trough so that a clear steam channel is provided to the steam outlet.

It will, of course, be understood that various details of the invention may be varied through a wide range without departing from the principles of this invention and it is, therefore, not the purpose to limit the patent granted hereon otherwise than necessitated by the scope of the appended claims.

We claim as our invention:

1. An instrument box for an automatic electrode-actuated foam control system which comprises a housing, a binding post panel fixedly mounted in said housing, binding posts on said panel adapted to be placed in electrical connection with the electrodes of the system and with a source of electrical current, conductor links adapted to connect various of said binding posts in accordance with the particular foam control system with which the box is used, a removable panel, electrical system controlled units mounted on said removable panel, and shiftable conductor links on said removable panel for varying the connections between the electrical control units in accordance with the particular foam control system.

2'. A terminal box for an electrical system comprising a rear wall; peripheral walls extending around a margin of said rear wall to define an open front housing; an apertured cover for closingthe open front of said housing; a first panel in said housing in spaced relation to said rear wall with one edge adjacent a peripheralwall; a second panel removably mounted in said;

on the second panel registered with the cover apertures to be visible therethrough.

3. A terminal box for an electrical system comprising a rear wall, top and bottom walls, and side walls, said walls together defining an open front housing; an apertured cover for closing the open front of said housing; a first panel in the upper portion of said housing in spaced relation to the rear wall; electrical devices mounted on said first panel; a second panel removahly mounted in said housing to extend below said first panel to the bottom of the housing thereby to divide the interior of the housing into separate front and rear sections; coacting devices on proximate portions of said panels for removably mounting the upper portion of said second panel on said first panel; and supports in the lower portion or the housing for removably mounting the lower portion of said second panel; separable plug parts on confronting proximate portions of the respective panels adapted for disengagement upon removal of the second panel; indicators on the front of said second panel registered with the apertures in said cover; and means in the bottom portion of the housing for receiving a device that has separable members one of which members is accessible for removal from the exterior of the housing.

4. A terminal box for an electrical system comprising a rear wall; peripheral walls extending around the margin of said rear wall to define an open front housing; an apertured cover for closing the open front of said housing; a first panel in the upper portion of said housing mounted upon supports projecting forward from the rear wall thereof to position said first housing in spaced relation thereto; electrical devices on front'and rear faces of said first panel; a second panel removably mounted in said housing to extend below said first panel to the bottom of said housing thereby to divide the-interior of the housing into separated front'and rear sections; the upper portion of said removable panel mounted on supports projecting forward from the lower portion of the first panel; electrical devices on the front and rear faces of said second panel and extending into the respective front and rear sections of the housing; supports for removably mounting the lower portion of said second panel; separable plug parts on proximate portions of the respective panels adapted to be disengaged upon removal of said second panel; indicators on the front of said second panel registered with apertures in the cover; and means in the bottom of said housing for receiving a device having a separable portion that is accessible for removal from the exterior of said housing.

5. A terminal box for an electrical system comprising a plurality of walls providing an open front housing; an apertured cover normally closing the open front of the housing; separate front and rear panels mounted in said housing in spaced relation to each other, one of said panels being fixedly mounted in the upper portion of the housing, the second panel being removably mounted in overlying relation to the other panel and supported at one end by said first panel;

adapted for removal with said panel; and indi-' cators on one of said panels registered with the apertures in said cover. I

' JAMES I-L'STARR. v

EDWARD A. GOODNQW.v 

